ASSIGNMENT

The assignment given to us is as shown in fig 1 we have to generate the CAD model out of the given Drawing and then will have to generate the Machining toolpaths for same.

Fig. 1This whole assignment is divided into 3 parts i.e. 1st is generating the CAD model out of 2D drawing 2nd is generating the tool path for that CAD model and 3rd is verification of toolpath. So we will be First concentrating on making the CAD model of above shown part.

EXERCISE

STEPS

1 st CAD Model Generation

1. First thing to make sure is that the unit should be in Metric (mm).

Fig. 2

2. As it is a turn mill operation we have to work in Right side plane. As in figure 2 you can see by default Mastercam opens in Top plane we will have to change it to Right Side plane by click on shortcut of Right side plane or we can go to View in that Standard View and their we can select Right (WCS).

Fig. 3

We can make sure that we are in Right side view by looking in Left bottom corner of screen as it shows Right Side View.

3. Now we will start the drawing of CAD model.

4. We will make a circle of Dia 100mm at a Depth of 120mm from origin, for that we will have to make some changes in Status Bar at bottom of screen.

Fig. 4by default we get 3D mode which is to be converted to 2D as shown and required depth is to be put in column as shown in figure 4. So we put -120 as depth.

5. We then make a circle of Dia 100mm taking origin as Centre.

Fig. 5

6. Then we will go to Solids in MENU bar and select Extrude command. It will as us for Chaining. Chaining is nothing but we have to give the area or the entity to which we want to apply the command in this case extrude.

Fig. 6As soon as you click on the Circle it will be selected for chaining. As shown below

Fig. 7Press OK after selection.

7. It will take us to Extrude option screen. Where we will put the height of circle i.e. 35 mm and to see the preview correctly we will see Isometric view, we can get to iso view by pressing Alt+7 or else we have a shortcut key on right side of Right side view key.

Fig. 8

Once done press on OK. and then get back again to Right Side view.

8. Next is we have to make a Hexagon with Circumcircle of Dia 70mm. at a depth of 85 mm. So first we have to select the depth of 85 mm as done above.

Fig. 9

after selecting Polygon option making Hexagon of it as below.

Fig. 10

9. Again extruding it till a distance of 20mm as done above. The output will be as shown below.

Fig. 11

10. Now we will Design Blade for that we have to Make upper drawing 1st which will be at origin i.e. at 0 Depth.

11. Make 2 point with Co-ordinates (-20,-9) and other one at (30,0). For that select Create Point position and select fast point option once its active then enter the co-ordinates.

Fig. 12

Similarly make other point at (30,0).

Fig. 13

After creating two points we will have to create circles with these two having these two points as Centre.

12. Two circle radius being 6mm and 3.5 mm.

Fig. 14

13. Now we have to create arc tangent to these two circles which is having radius of 70mm. For that we will have to select option CREATE in Menu bar in that ARC option and in that we will select ARC TANGENT from drop down menu list as shown below.

Fig. 15Once in this option we will have to select Arc tangent 2 entities also enter the radius i.e. 70mm.

Fig. 16Select the two circles to be tangent. We will get all possibilities of making that circle out of given inputs as shown below.

Fig. 17

Selecting fillet that has been coloured black and white in above figure.Then again repeating the same procedure and selecting black and white coloured line in below figure.

Fig. 18

Once we are done with this we will get following result.

Fig. 1914. Next step is to trim two circles.

15. Select Trim/Break/Extend option as shown below and in that select Divide/Delete option. Once selected delete the extra or inner part just by clicking on it, of circle to look like below figure.

Fig. 20

16. Next step is to draw the lower part of blade.

17. For that we will have to copy and move upper curve at depth of 65mm.

18. We will use TRANSLATE option present in XFORM Menu Bar.

Fig. 21

19. Once selected it will ask us to select the entities to be translated. Select the upper curve as shown.

Fig. 22

20. Then in Translate Menu put value -65 mm in Z column and press OK. our entity has been translated to a depth of 65mm.

21. Now we have to rotate the lower curve at an angle of 15 degree from centre, before that we can confirm the same by viewing the isometric view as shown below.

Fig. 23

22. To rotate select Rotate option from XFORM menu bar and select the Lower curve. Make sure you have selected lower curve only by going into Isometric view and then once confirmed again come back to Right side view.

Fig. 24

23. In rotate option put -15 degree in angle column and make sure you have selected Move option from top of rotate menu.

Fig. 25

24. Once done press OK.

25. Now we have to make a Solid body between these two curves. That will be done by LOFT option present in SOLIDS option.

26. Select LOFT option. Also come to Isometric view for same.

27. It will ask you to select the two curves between which the Loft is to be generated select the curves as shown below. Then press OK.

Fig. 26

28. It will take you to Loft Menu here also just press OK after seeing the preview.

Fig. 28

29. Now we will have to make Slots on Hexagonal faces, for that we will have to Work in Top view selecting TOP view as we selected Right Side view.

30. For making slot we will have to first draw a Point at (-75,0) at a distance of 35mm above origin that will be the centre of slot that we will make.

Fig. 29

31. For making Slots we will select RECTANGULAR SHAPES from CREATE Menu bar.

32. In Rectangular Shapes Menu we will select Anchor point to be Centre point then the shape would be Slot type Obround shape and then slot height would be 15mm and width would be 6mm as shown in fig. below.

Fig. 30

33. Select the centre point Created before to draw the slot as shown above.

34. Now we have to Cut this slot till a distance of 5 mm.

35. Go to Extrude option. Select the chain i.e. slot that we created. Go to Iso view. Select Cut Body option Change the direction and put distance 5mm.

Fig. 31

36. Now we will have to revolve this Cut pattern into along all faces of Hexagon.

37. Selecting CIRCULAR PATTER from PATTERN option in SOLIDS option from Menu bar.

38. On selecting the CIRCULAR PATTER it asks us the target body which will be Hexagon so select the hexagon then it will ask us to select the Solid Operations to be patterned. So now selecting the Slot hole created as shown below.

Fig. 32

39. Pressing OK after selecting the Operation.

40. Now go to Right Side view and then in Menu Select Full Circle and instances to be 5 and say OK. Make sure to go in Right Side View as shown below.

Fig. 33

41. We are done with CAD Model preparation.

Fig. 34

2 nd Toolpath Generation

1. The first thing that we have to select is Machine type i.e. What we call are Controllers. So we have to go to MACHINE TYPE option in menu bar an then in LATHE in that it will open a drop down menu which will show all the default controllers available with Mastercam. We will select Default for our practice.

Fig. 35

2. Now Next step is to define the RAW Material, we call it STOCK SETUP in Mastercam.

3. We will have to double click on Properties Icon as shown below.

Fig. 36

4. Click on Stock Setup under Properties.

5. We will get a menu bar where we have to Define the stock and the below that the chuck.

Fig. 37

6. Click on Properties in Stock setup to define Raw material.

7. As we go in properties of stock we have to select ‘Make from 2 point’ option.

Fig. 38

8. after selecting that option it will guide you to model where you have to select two diagonal point covering the maximum part, the point in this case will be as shown below.

Fig. 39

9. Then select ‘Use Margin’ option to make margin for same. Give value 5mm for OD margin, 5mm for Right margin and 25mm for left margin.

Fig. 40

10. Press OK when done.

11. Now again go to properties of CHUCK JAWS. In that turn on ‘from stock’ option and give value 15mm in ‘Grip Length’.

Fig. 41

12. Press OK when done. You will see figure as shown below.

Fig. 42

13. Now you Raw material is ready now we know what we have and what we want to have.

14. Facing toolpath generation Select Face toolpath from Toolpaths menu. It will ask you to enter NC name enter and proceed. Then a Lathe Face Properties dialogue box will appear.

Fig. 43

Tool Parameters- Select the tool. We will select T0101 R0.8 OD ROUGH RIGHT- 80 DEG. We can edit the tool insert by double clicking on tool even the holder and all the parameters related to tool can be edited. Outside also we get the parameters like feed rate, finish feed rate, spindle speed, finish spindle speed, max. spindle speed can be edited.

Face Parameters- It is mainly asking for what is the amount of stock to be faced. Again we can give it manually (Use stock) or automatically (Select points) we will go for automatic click on select points shown below.

Fig. 44

In this it asks for the area till which the stock is to be faced. Select the area as shown below. Edit other parameters such as turn on Rough Stepover option and let the distance be 2mm and say OK.

Facing is done and we will get following toolpath.

Fig. 45

15. Next step is to make the turn profile.

16. Select TURN PROFILE option in CREATE menu and then select the complete Part and then say OK . We will get a profile which can be used for turning.

17. Roughing Operation

Select the Rough Operation from Toolpath menu Select the chain as shown.

Fig. 46

Again lathe rough properties dialogue box will appear having two tabs to define. Toolpath parameters and Rough parameters.

Toolpath Parameters- Select same tool as before and change the parameters as required.

Rough Parameters- Main thing to remember here is to select ‘Use stock for outer boundary’ in “Stock recognition”. If this is not done the toolpath will not be generated according to stock it will be generated according to defined part which may lead to collision. Rest other parameter can be varied accordingly. We will use the same as defined. Say Ok.

Fig. 48

We will get following toolpath.

Fig. 49

18. Facing Toolpath Select the Finish Operation from Toolpath menu Select the chain for surface to be finished. For our example we will select

same as before, for this we have one option called LAST in chaining menu which automatically select the last chain as select by us before click on it.

Fig. 50

Again lathe Finish properties dialogue box will appear having two tabs to define. Toolpath parameters and Finish parameters.

Toolpath Parameters- We will select T2121 R0.8 OD FINISH RIGHT- 35 DEG. tool and change the parameters as required as shown.

Fig. 51

Finish Parameters- Here the finish parameters Finish Stepover & Number of finish passes are important. We will give Finish stepover as 0.5 and Number of finish passes as 2. And say OK.

Fig. 52

We will get following toolpath for finishing operation.

Fig. 53

19. 2D Contour Select the CONTOUR toolpath in MILL option from TOOLPATH menu. Come to isometric view for selection.

Fig. 54

Select the chain as shown in figure and say OK.

Fig. 55

As the 2D contour toolpaths Menu opens. Directly go to Planes (WCS) option in Menu and change Tool plane view to Right View and also Comp/Construction Plane to Right view.

Fig. 56

Then go to Tool- In this you can either Create new tool by right clicking in the List screen and selecting Create new tool then selecting proper tool type and then entering the required values of tool. Else you can select from library by clicking on Select library Tools.

We will select from library 16.FLAT ENDMILL (dia16)( Keep Overall height of 110 and cutting Length is 100 as per our part) .

Holder – You can edit holder dimensions in there. (default) Next comes the Cut Parameters which has following options:-

o Compensation Type- It means what type of tool radius compensation you

want to give, it can be Computer that means computer controlled or Control that means you have to take care of compensation or Wear which means you have to give the toll positive tool wear value or Reverse wear which means you have to give negative tool wear value or you can Off it also. (We will keep it Computer)

o Compensation Direction- It ask the direction from which the

compensation will be either from left or right it depends on the direction of chaining you have selected in chaining option i.e clockwise or anti-clockwise. (We will keep it Left as our chaining direction is Clockwise)

o Tip Compensation- It ask for tip compensation either from tip or from

centre. (Tip)o Roll cutter around Corner- You can keep it None, Sharpe or All. (Sharp)

o Internal Corner rounding radius- you can give the corner rounding radius.

(0.0)o Stock to leave on walls/floors- It asks for stock to leave on wall for finish

cuts.(0.0) Depth Cuts- It ask for the depth of Cut that means for one cut till what depth it

should cut then it also asks for Finish cuts i.e number of finish cuts you want and then finally the distance between finish steps (Max Rough step- 5 , Finish cuts-2, Finish step-0.5).

Note- the depth of cut depends upon the Material of Stock and Tool.

Lead IN/Lead OUT- It is option for Entry and Exit of tool it has many options, you can control with right from Perpendicular or Tangent Entry and exit to the Line and Arc of entry and exit. (Default)

Break Through- It is option for tool going pass the edge of the part or not. You can decide the length of it or you can close it. (Off)

Multi Passes- This option is for no. of passes you want to give on contour face. You can decide the number of passes the distance between the passes and same for finish cut. (Off)

Tab- You can define the tab in if required in this option. ( We will keep it off) Linking Parameter- It has following important options to define-

o Clearance- It is the height till which the tool comes from home position in

rapid mode. (We will give of 50.0)o Retract- It is the height till which the tool Retract after each Depth of Cut

rapidly. (We will give of 25.0)o Feed Plane- It is the height from which the tool will move in with defined

Feed rate inside the part. ( We will give of 10.0).

o Top of stock- As said you have to define the top of stock (Our top of stock

will be -65). o Depth- Again you have to give the depth of part (Our depth will be -85).

We have selected both the distances by clicking on the icons and selecting it from the screen itself.

The generated Toolpath is as shown below.

Fig. 57

20. Pocket Select Pocket toolpath from Toolpaths menu in MILL option. Now it will ask for chaining, select 1st and only slot pockets as shown in figure.

Fig. 58

Then a 2D Toolpaths-Pocket Dialogue box will appear. Tool Type- Pocket. Tool- Select the tool as per defined in contour operation. We will select from library 5 FLAT Endmill Cutter (Dia-5).

Fig. 59

Holder – You can edit holder dimensions in there. (default) Cut Parameters-

o Machine direction- We need to define the machining direction it

could be Climb or conventional. (We will keep it Climb)o Pocket type- Standard.

o Tip comp.- Tip

o Roll cutter round corners- Sharp

o Stock to leave on walls - 0

o Stock to leave on floors- 0

Roughing- This will create the rough profile of pocket followed by finish machining. We can define the tools path. (We will keep Parallel Spiral).

Entry motion (for Roughing)- You can define the entry of the tool and various parameters related to it. (We will keep it Default)

Finishing- This is the finishing pass of pocket. (We will give Passes-1, Spacing-0.5, Spring passes-0, Cutter compensation- Computer, rest everything is default).

Lead IN/Lead OUT- It is option for Entry and Exit of tool it has many options, you can control with right from Perpendicular or Tangent Entry and exit to the Line and Arc of entry and exit. (Default)

Depth Cuts:- It ask for the depth of Cut that means for one cut till what depth it should cut then it also asks for Finish cuts i.e number of finish cuts you want and then finally the distance between finish steps (Max Rough step- 2 , Finish cuts-1, Finish step-0.5).

Break Through- It is option for tool going pass the edge of the part or not. You can decide the length of it or you can close it. (Off)

Linking Parameter- It has following important options to define-o Clearance- It is the height till which the tool comes from home

position in rapid mode. (We will give of 50.0)o Retract- It is the height till which the tool Retract after each Depth of

Cut rapidly. (We will give of 45.0)o Feed Plane- It is the height from which the tool will move in with

defined Feed rate inside the part. (we will give of 40).o Top of Stock- Define the top of stock. (ours is - 35 )

o Depth- Give the depth of part (Our depth will be - 30).

The generated toolpath is as shown below.

Fig. 60

21. Toolpath Transform Go to TOOLPATH TRANSFORM toolpath in TOOLPATHS menu bar. Transform Operation Parameter menu will open where we have to define

all the parameters related to to it. We will first edit TYPE AND METHODS bar. In Type – select ROTATE. In Method – Select TOOL PLANE. In Source Operation – Select POCKET (Standard)

Fig. 61

Now we will edit ROTATE bar. In INSTANCES- 5 (#). Both Angles be – 60 degree. In Rotation Plane – Right Side Say OK when done.

Fig. 62

We get following toolpath.

Fig. 63

22. Stock Model Now what we are going to do is . We will make a Solid of machined part i.e.

till now what what all operation has been performed we will see the cut part of it. It will also act as reference to next toolpaths.

Select STOCK MODEL toolpath from TOOLPATHS Menu bar. In STOCK DEFINITION

o Name- ABC

o Initial Stock Shape – Stock Setup. It will automatically take the

stock value initially defined in stock setup.o It will automatically take all the value of initial defined stock

Fig. 64

In SOURCE OPERATION o Compute Stock Model from – Select all the toolpaths by pressing

Ctrl and selecting it one by one.o Say OK when its done.

Fig. 65

We will get following Model after the above operations.

Fig. 66

23. Dynamic OptiRough Toolpath (TOP) -

Before starting this toolpath we need to make a containment boundary which means the cutter will be inside that boundary only. So we will make a random rectangle as highlighted in below figure.

TOOLPTHS menu bar we will have to go to MILL in that SURFACE HIGHSPEED toolpaths and in that OPTIROUGH TOOLPATHS.

As soon as you click on above toolpath it will ask you to select drive surface. Select complete model as drive surface.

Fig. 67

Tooltype- Roughing ; Dynamic optirough Tool – 8 BULL MILL Cutter 2 RAD. Holder- Default Cut Parameter

o Cut Style- Default

o Passes – Stepover : 45% ; Steep Down : 10% ; Stetup : 5%

o Rest default

Fig. 68

Rest material – Check ON rest material option and select ‘One other operation’ option and in that we have to select last option i.e. Stock Model

Fig. 69

Tool Containment – inside Transition – Default Steep/ Shallow – Check ON , Z depth , minimum depth : 35mm, maximium

depth : -10mm

Fig. 70

Linking parameter – o Retracts – Instead of “Full Vertical Retracts” make it “Minimum

vertical retract”o Fitting – Instead of “Minimize Trimming” make it “Machine entire

pass”

Fig. 71 Toolpath

Fig. 72

24. Dynamic OptiRough Toolpath (BOTTOM) – Just copy the above toolpath below it. as shown below.

Fig. 73

Go to Parameter option in this copied toolpath. Go to PLANE (WCS) – change Tool plane and Comp/Construction plane to

BOTTOM

Fig. 74

Go to Steep/ Shallow option – Change the maximum depth to -1. Regenerate the toolapth. Toolpath

Fig. 75

25. MULTIAXIS Go in TOOLPATHS menu bar in that MILL drop down menu in that

MULTIAXIS.

Fig. 76

Once selected Multiaxis Select Tool Type - ROTARY

Fig. 77

Tool – 9 BALL END MILL Cut Parameter

o Surface – as shown below

Fig. 78

Tool axis controlo Axis Dampening Length – 1 mm

o Maximum step – 1 mm

Keep rest setting default. Toolpath

Fig. 79

3 rd Verification of toolpath

26. select all the toolpath by clicking on below button

27. Click on verify selected operation by clicking on following button and you can see the solid simulation of part.

28. Click PLAY on Simulation screen and you will the cut part.